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Buell Motorcycle Forum » THUMPer Forum » Buell Blast Thumper Knowledge Vault » Engine - all topics related to the Motor » Primary Drive and Transmission » 02 Blast, second "clunk" as I let out the clutch « Previous Next »

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Slowhand96
Posted on Friday, December 22, 2006 - 11:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Hi all,
I'm new to this world of Buell Blasts, but lovin' it. I jumped in with both feet (and more) and bought three blasts from an MSF Motorcycle Safety provider in Minneapolis, that I teach for. I'm pretty handy with my Road king but these buells have me stumped, and it doesn't help that the service manual I bought seems to be wrong and worthless on many topics. Sorry I tend to ramble. All three bikes have minor issues but the bike I intend to keep is the problem child. It has the traditional "Clunk" when I put it in gear then a second similar "Clunk" as the bike begins to roll (after a couple of feet). It will only do this after it has been in neutral. It will not do it if I stop and hold the clutch.
Any clues what direction I should look in?
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Swampy
Posted on Saturday, December 23, 2006 - 01:34 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Welcome to the board Slowhand96!

The second clunk, I have noticed it with both my Blasts. There are a couple of things to check for:

Make sure the primary chain is adjusted properly. The Blast likes a loose adjustment much more so than anything you are used to, there is much discussion in the Thumper Knowledge Vault about this.

The second would be make sure the clutch is adjusted properly.

The third is the crankshaft flywheel sprocket nut.

I would also make sure the front engine isolator and engine mounting bolts are in good shape.

Three Blasts...How Cool is That?!!!
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Buellistic
Posted on Saturday, December 23, 2006 - 08:44 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Slowhand96:

You can not be referring to a FACTORY SERICE MANUAL ???

QUOTE: the service manual I bought seems to be wrong and worthless

In BLASTing
LaFayette

(Message edited by buellistic on December 23, 2006)
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Slowhand96
Posted on Saturday, December 23, 2006 - 11:56 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Buellistic, "You can not be referring to a FACTORY SERVICE MANUAL ???" Yes I am referring to the factory manual. Am I the only one? BTW. the manual says 1.5 quarts of oil, I filled the new filter with oil, then put in the remaining oil to total 1.5 quarts, I wasn't even on the stick yet. After warming the bike I had to put the rest of the last quart to get it to the proper level. Is this the norm?
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Ezblast
Posted on Sunday, December 24, 2006 - 12:01 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

2 qts - +/- a few ounces - lol
GT - JBOTDS! EZ
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Slowhand96
Posted on Sunday, December 24, 2006 - 12:06 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Thanks for the warm welcome!

Yes THREE!!! Got a great deal too. A black 2000 1500 mi, and a yellow 2002 with 2600 mi and a black 2002 with 1400 mi. The yellow one is the problem child and being the way I am thats the bike I'm going to keep and probably sell the other two.


Swampy, The primary chain adjustment was the first thing I tried. That's why I bought the service manual. I have since re-adjusted it to "Thumper Forum" spec. The clutch was the second thing I tried, it is adjusted as per the manual, is this info incorrect too?

I did a visual inspection of the mounts but I'll take a closer look and push and pull on things. If I don't find anything there, I'll go in and check the sprocket nut too.
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Gearheaderiko
Posted on Sunday, December 24, 2006 - 12:25 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Yes, there are mistakes in the factory repair manual (and owners manual). I wouldnt say its worthless, but if you can actually figure out where the mistakes are, then it should suit you just fine. You obviously know how to wrench on stuff.
Welcome!

PS Did you do a Badweb search for "2nd clunk"? I know you're not the first person to bring this question up.
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Buellistic
Posted on Sunday, December 24, 2006 - 12:51 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Well, Well, "i" have been saying this for
years !!! You just have to learn to seperate the "BUELLschitte" from reallity ... PLUS WE ARE SUPPOSED TO PROOF
READ THEM FOR THE FACTORY AND REPORT SAID
MISTAKES ON THE PROVIDED FORM(make sure you make copys of this form as there are many mistakes) ... Do not forget to say how to do the task correctly !!!

In BLASTing
LaFayette
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Xgecko
Posted on Sunday, December 24, 2006 - 12:53 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I have always laughed when I read that because my Blast takes about 1.8 to 1.9 Qt's if I put 2 Qt's in, I get a leak out top and all down the front. I've only made that mistake twice and that was separated by 5 years
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Gearheaderiko
Posted on Sunday, December 24, 2006 - 01:39 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

" PLUS WE ARE SUPPOSED TO PROOF
READ THEM FOR THE FACTORY "
I'm sure thats going to sell a lot of Honda's !!!
Its no wonder that I cant get anybody to buy a Buell!
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Swampy
Posted on Sunday, December 24, 2006 - 01:27 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

LOL!!~

You guys crack me up!

As for the clunk, check for the drive belt missing teeth. What else? Maybe transmission wind up? Clutch wind up, clutch plates too loose in the clutch hub?

The only other thing the clunk could be is something internal, so for the while, until the next catastrophical faliure occurs leaving me stranded in BFE, its gonna get ridden, because sooner or later, if its meant to break, the Big Kid is gonna do it.
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Swampy
Posted on Sunday, December 24, 2006 - 01:34 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

But thinking about it now for a while I think the more plausible explaination is that the transmission being what it is, when you shift the shift drum into gear, the dog ears don't slide fully into place, leaving the gear not fully engaged until it starts moving, then once it starts to move the dog ears move around, it lines up and you get that clunk sound/feeling as the tension on the shift forks push the gear into place.
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Jprovo
Posted on Monday, December 25, 2006 - 06:42 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Swampy, I agree with your assessment of the problem. It happened occasionally on my 2002 Bike with 43,000 Miles. You can try to adjust the shifter pawl mechanism to get it to stop. - James
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Joey
Posted on Tuesday, December 26, 2006 - 07:45 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Swampy's got it. Mine does that a lot. If you get the first clunk, then try to push the bike, it won't move because the transmission is halfway somewhere. I ease the clutch up, and I can feel it moving into first gear. A quicker let up of the clutch puts in a second clunk. I love the look my wife gives me when she's nearby and I put it into gear when it's cold! CLUNK! I could have patience, pull the clutch, and wait a little longer, but that's just not my style.
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Slowhand96
Posted on Tuesday, December 26, 2006 - 11:03 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Swampy

I had a "gut" feeling that the clunk might be what you were just describing with the transmission gear teeth not engaging fully. After the clutch and motor mounts this is the third item that I sought to check out, the shifter pawl, but... this is another section of the manual that seems to be "worth less" than what it could be. Items are misidentified in some of the illustrations and the procedure seems to start out OK then switch to a different procedure half way through. Just confusing enough to make me set down the wrenches and back slowly away from the problem child.
I love your trouble shooting technique, "because sooner or later, if its meant to break, the Big Kid is gonna do it." go for failure and remove any doubt! LOL.. I had a triumph (car) TR8 a while ago, talk about the black hole of wiring systems! My sure fire way to find a shorted wire was to replace the fuse with a screw, the spot that melted and burned was my trouble area. LOL..
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Slowhand96
Posted on Tuesday, December 26, 2006 - 11:12 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Xgecko

You are right, my bad.. LOL.. there is an oz. or two of oil left in the bottle.
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Gearheaderiko
Posted on Wednesday, December 27, 2006 - 12:50 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Exhaust questions moved to the exhaust thread
http://www.badweatherbikers.com/buell/messages/201 64/6806.html?1166487147
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Luvdathump
Posted on Monday, August 24, 2009 - 02:07 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Hey guys miss me? I am still having problems with my transmission. I adjusted my clutch just as the manual stated, well kinda. Instead of the primary adjustment screw they point too I turned the screw behind running through the lock plate. Anyways I'm still getting a second clunk in first gear. When I go from neutral to first is when it happens. it seems to act like the tranny is not all the way engaged until I roll a few feet. So I guess the questions I have are, could I possibly misadjusted the screw I went a 1/4 turn from light bottom. Also as I was scanning the manual busting into the primary looks like a pretty big job. Is it easier than the manual makes it look? I'd really hate to get knee deep into it and realize I'm in over my head.
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Swampy
Posted on Monday, August 24, 2009 - 09:24 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I think that the thunk you are hearing is the shift dogs fully seating into the gear. I wouldn't worry about it. I would simply remember it and remenise back on it when you are old....as in "Boy, remember how those Blasts used to shift?"

I think that the only way you are going to cure it is to have the shift dogs back cut so they drive themselves into each other.
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